Cable joint and method of forming same



1, 1941- E. mLuA-Ms ETAL 22 6.862

CEBLE JOINTAND METHQD OF FORMING SAME Filed NOV. 15, 1939 2 Sheets-Sheet 1 I; JNVENTORS ERA/E57 WILL/4M5 cp /snwrms xmis Y ATTORNEYS April 1, 1941. E. WILLIAMS EIAL CABLE JOINT IND METHOD 'OF TURNING SAME Filed Nov. .15., 1959 251169129-511866 2 ATTORNEYS Patented Apr. 1, 1941 2,236,862 CABLE JOINT AND METHOD OF FORMING SAME Ernest Williams, Jackson Heights, and Constantine P. Xenis, Little Neck, N. Y., asslgnors to Consolidated Edison Company Inc., New York of New York,

York, N. Y., a corporation of New Application November 15, 1939, Serial No. 304,566

6 Claims.

This invention relates to improved methods of forming cable joints and means therefor, and is particularly applicable to joints in electric power cables and electrical communication wire cables of the types enclosed in lead or other metallic sheaths.

Joint constructions for lead covered cables and the like are customarily covered, protected and strengthened by a lead or other metallic sleeve enclosing the spliced portions of such cables. For many years it has been the practice to effect a seal between the ends of such sleeves and the cable sheaths by beating in the ends of the sleeve to an extent such that the peripheral edges contact with the cable sheath, and then the region at the end of the sleeve is wiped by hand with solder chilled to plasticity. Such wiping operation has to be performed by skilled workmen who have gone through a considerable period of training if the occurrence of leaky or porous wipes is to be avoided, even with cables of relatively small size. However, with the use of cables of larger size requiring larger wipes, and particularly with complicated joints or where two or more cables enter the sleeve at one end of the joint, there is great difliculty in securing reliable wipes and only a small portion of the more skillful and experienced workmen trained in this art are able to accomplish the task, and oftentimes the operations have to be repeated again and again beforesuccessfully-completed.

In performing the wiping operations, solder is melted in a pot, and then poured by the use of a hand ladle on to the area of the desired wipe. A portion of the solder thus poured adheres in plastic condition to the cable sheath or the Sleeve, provided the poured solder is at the proper temperature, and the wiping pad held in the hand of the operative just beneath the cable. This pouring operation is repeated again and again, while the pad with solder thereon must be skillfully wiped over the area of the desired seal until a suificient mass of plastic solder is built up to form a poultice-like seal between the sleeve and cable Sheath. The difficulties with this method arise from various If the solder is too hot or if too much solder is poured on to one area, either the sleeve or cable sheath will be burned quickly through, that is, a hole will be melted through, ruining the joint or the cable Also, particularly with the larger joints, if the plastic mass of Solder as it accumulates on the joint, is slightly too soft, it may collapse and fall away, requiring the operative to start anew. Again, if the mass of solder remainder is received in a solidifies before a smooth continuous wipe has been formed, crevices and irregularities will occur impairing the strength and durability of the seal or affording areas prone to leakage. While such an imperfect joint might be glazed and sometimes corrected by applying a blow torch, the use of open'fiames in underground manholes or passages offers a hazard from gas explosions and is therefore generally prohibited. There is a relatively narrow temperature range of plasticity required of the solder to permit sufficient workability and this necessitates skillful timing of the operations in forming the wipe. Solder with 40% tin and 60% lead as normally used for this type of work, has a plastic range of approximately 55 C., or from about 238 C. down to 188 C., the latter temperature being the solidifying point of the eutectic mixture (63% tin and 37% lead). In the wiping process as the solder is cooled to a plastic workability, there is a solidification of lead particles or crystals at temperatures above 183 C.-, the solidifying point of the eutectic mixture. Yet due to the fact that the eutectic mixture remains liquid down to 183 C., it tends to run out of or to the bottom of the mass being formed, leaving the wipe coarse or porous toward the top. This effect-is particularly pronounced in larger wipes. For example, it has been found very diflicult to secure reliable non-porous wipes on the larger cables without resorting to the hazardous glazing process.

Further disadvantages of the customary wiping process reside in the following facts. The necessity of maintaining a pot of the molten metal at hand, particularly in confined spaces during underground work, is a dangerous hazard, as is also the ladling and pouring of such metal. The operfatives are frequently seriously burned. The heating in of the sleeve for complicated joints requires much time, and skilled work. Often supplemental end parts must be formed and fitted, on the job, between a plurality of cables. The wiping operation for each large joint requires the services of the skilled operative for several hours even if the operations do not have to be repeated. And the quality and useful life of the resulting joint often depend largely upon chance and the skill of the workman.

While efforts have been made for years to provide some method of avoiding the above difliculties and hazards, so far as we are aware such efforts have not, prior to our invention, produced any substitute method or construction which has gone into any substantial practical use in replacement of the manual wiping operation.

The objects of this invention include the provision of improved joint constructions and methods of forming same which will avoid in practice, the above mentioned difliculties and make possible the formation of more dependable and uniformly satisfactoryseals, with a substantial-saving of time and without requiring the operative to have any high degree of skill or long experience. Various features of the invention are also applicable to the problem of sealing metallic sheathed cables within terminal bushings or the like, for example at points where the cables enter a transformer or other piece of electrical equipment.

Various further and more specific objects, features and advantages will clearly appear from the detailed description given below taken in connection with the accompanying drawings which form a part of this specification and illustrate merely by way of example preferred forms of the invention. The invention consists in such novel methods and method steps, features, arrangements and :ombinations of parts as may be shown and described in connection with the con- .structions herein disclosed.

In the drawings, Fig. 1 is a. vertical sectional view taken longitudinally of a cable joint, with sealing means prepared in accordance with this invention and showing the condition of the assembled parts just prior to the final sealing operations;

Fig. 2 is a similar sectional view of a completed and sealed joint made according to the invention;

Figs. 3 and 4 respectively are transverse sectional views taken substantially along the lines -3-41 and 4-4 of Fig. 1;

Fig. 5 is a longitudinal sectional view of a modified form of the invention;

Fig. 6 is a sectional view illustrating the manner in which external heating means may be applied to the joint sleeve during the sealing operation; and' Figs. '7 and 8 respectively are longitudinal and transverse sectional views of a further modification of the invention.

Referring now to Figs. 1 to 4, a joint construction is shown enclosed by a substantially cylindrical lead sleeve as at Ill, the sleeve having a single lead sheathed cable, for example as at H, extending into one end, and four lead sheathed cables as at I! to L5 inclusive, extending into the other end. Suitable insulated electrical joints or splices may be made between the various cable ends within the sleeve as at it according to wellknown methods, which need not be here further described. In all of the Figures 1, 2, 5 and 7 the mid portions of the joint are broken away and not shown, since these portions may be constructed in accordance with well-known methods.

In forming the joint, before the ends of the cable are spliced together and wrapped with insulation, the sleeve ill may be threaded on to one of the cable ends (or on to a group of the cable ends if a plurality of cables are to enter one end of the joint), as may also a'pair of barrier members as at I! and I8 with a precast member of solder is interposed therebetween. The construction and use of these members will be explained further below. Also an inner sleeve of suitable rigid insulation material as at l0 may be inserted in the sleeve ID at this time. At the other end of the joint prior to splicing the cables, similar barrier members as at 20, 2| and a precast solder member 22 are threaded on to the adjacent cable ends. It will be apparent that during the work of making the electrical connections and the insulation thereof at IS, the sleeves as well as the barrier members and precast solder members may be slid back along the cables so as to afford ready access to the region of the splice.

The inner surfaces at the ends of the sleeve are scraped clean and coated with stearin or other flux material, and the surfaces of the cable sheaths at the areas of the desired seals are similarly prepared.

After the splicing and the insulation work is completed as at IS, the sleeves l0 and ID may be slid over the spliced region to the position shown in Figs. 1 and 2. Thereupon the barrier members i8 and 2! may be forced into the positions as shown in these figures and respectively abutting the ends of the insulation sleeve i0, so that such ends serve as stop means preventing further displacement of the barriers inwardly of the joint. Thereupon the precast solder members i9 and 22 may he slid into the positions shown in Fig. 1 and finally the outer barrier members i1 and 20 may be forced into place. The edges of the sleeve ill at its ends are preferably slightly flared outwardly as at 23 to facilitate introduction of the barrier members into the sleeve. The lead sleeve is next tapped circumferentially on its exterior at the region of each barrier to assure a tight fit.

The barrier members 11, i8 and 20, 2| may be formed of cork or other suitable material or composition capable of withstanding the temperature of molten solder, and preferably a somewhat yieldable material which may be pressed firmly into place in the space between the cable sheath and the sleeve to prevent passage of molten solder along the surfaces of either, during formation of the seal as hereinafter described. A composition of cork and synthetic rubber known in the trade as Corprene" has been found satisfactory. It will be understood that the peripheries of each of the barriers are cut to firmly fit within the inside walls of the particular sleeve to be used therewith, and that suitable apertures are also cut through the central areas of each barrier for permitting the desired cables to pass therethrough, the apertures being of such size that the cables will fit quite snugly therein. It is noted that the barriers also serve the function of properly supporting the cables in predetermined desired spaced positions in respect to the sleeve and each other during the sealing operations.

Also the outer barriers i1 and ably, as shown, formed with a number of apertures for receiving thin walled tubes of copper or other heat conductive material as at 25 to 21 inclusive. As hereinafter explained in further detail, these copper tubes are adapted to receive eleotnical resistance heaters of the cartridge type, for heating the solder during the formation of the seal.

The precast solder members as at l9 and 22 may comprise disc-like walls or masses of solder previously cast in suitable forms or molds and of such size at their peripheries to loosely fit into the sleeve i0, and being formed with apertures or cut-out areas as at 28, 29, 30 (Figs. '3 and 4) to permit the cables to rather 1005811 pass therethrough. Also preferably during the casting of these solder members, the tubes as at 25', 26, 21 are so mount-ed in the molds that they will be retained in the solder when solidified, in the desired positions as shown in Figs. 1 to 4 inclusive. It will be noted that the inner ends of the tubes 20 are preferside walls of the sleeve.

With the joint assembled as in Fig. 1, the operations for sealing the ends of the sleeve to the cable sheaths may now be undertaken. Electrical cartridge type heaters as at 33 of well-known construction may be inserted in each of the tuba as at 245, 21. A controlled amount of current may then be passed through the resistance coils of these heaters for a time sufficient to melt the cast solder members, but without danger of melt o facilitate both the insertion and removal thereof.

If t any subsequent time, it is desired to open the joint, cartridge heaters may be inserted again readily replaced by a splice with additional or larger cables, for example.

Then the joint may be sealed again as before.

The upper ably be provided with a pair of apertures closed by screw plugs as at 34. iThese screw plugs are preferably removed during the sealing operations so as to relieve any gas pressures which might otherwise occur within the joint due to th heating of the ends thereof.

of these openings while the other acts as an air vent.

For joints of relatively small size, sufiicient heat for melting the solder may be applied by external heating means such for example as illustrated in Fig. 6. Here an annular heating member is shown at 35 for encircling the sleeve I 0 at the region of the desired seaL- This heater may comprise electrical resistance wires as at 36 with connections as at 31, the wires being enclosed in suitable flexible insulating material such as asbestos 38. This heating assembly may be made in the form of a flexible or semi-flexible band of a suflicient width to heat the entire end areas of the sleeve. The heating unit if desired may be made of two semi-circular sections hinged as at 39 on one side and secured at the other side as by a removable clamp 40. Such an external heator permits the end of the joint to be quickly hated before the heat has opportunity to injure the cables. If desired, the heating means of Fig.

to supplement th cartridge heaters above described, and for retarding dissipation of heat from the latter.

While the particular joint shown in Figs. 1 to 4 is a so-called "one-way x four-way joint, it will be understood that the invention is equally applicable to either simple joints of a single cable end to another cable end, or to joints having a sheathedcables of various different therein, or may be for telephone, telegraph or other communication purpose With the methods and constructions above described, it has been found that operatives, even seal complicated and large sized splices in a fraction.

of the time required for the usual wiping process.

At the same time the operatives are not subjected to the hazards of working around or with open That is, all of the solder Pressure tests made on joints compl t in a cox dance with this invention and under practical conditions in the field, show that with both high and low voltage cable systems, reliable seals may a high degree of uniformity, dependability and certainty. The resulting construction comprising rigid disc-like members of solder effectively made integral within the ends of the sleeve, serves to greatly strengthen the joint contraction of the heavy cables.

Since with this invention the heat may be applied by the cartridge heaters directly within the precast members of solder, these members may having internal and external annular reces'sesfor to the solder are cleaned be Quickly and uniformly heated in molten condition before there. is any danger of melting or injuring by heat, the cables, cable sheaths or the lead sleeves. Since the heat is applied electrically while the solder is in .place, the amount of heat may be accurately controlled, and skillful timing of the motions of the operative as necessary in pouring and wiping is obviated. The time and skilled labor required for properly beating in and fitting the sleeve ends and parts for wiped joints are obviated, as are also the uncertainties and defects of such method.

In practising this invention the solder com- I position used mayibe selected without adhering to the r uirements of obtaining a plastic mixture over any substantial temperature range. A solder comprising 50% lead and 50% tin has been found satisfactory and the resulting cast walls of solder are substantially homogeneous throughout, and the porosity encountered in hand-formed wipes is eliminated. The solder mixture remains essentially constant as it is retained in the cast-' ing cavity.

' Since a definite plastic range is not required of the solder for this method, it is possible if desired to choose a solder mixture close to the eutectic, thereby requiring less heat for melting, with less chance of injury to the cable insulation. i

Another embodiment of for use in some cases is Here the cables or conduits to be joined are indicated at M and M and the joint structure may be enclosed in a. lead sleeve 42, the same or similar if desired, to the sleeve l0 above referred to.

The splice construction within the joint is indicated at 43. In this casethe barrier members as at M to 41 inclusive may comprise annular members of lead or other suitable metal, and each the invention suitable 30 illustrated inFig. 5.

receiving gaskets as at 48 and 49. These gaskets may comprise annular rings of rubber or a comv position for example of artificial rubber and cork or other suitable material, preferablysomewhat yieldable and capable of pgeventing passage of the molten solderfrom the cavity formed between each pair of barriers. After the barriers arein place as indicated in Fig. 5, the cavity between each pair may be filled with molten solder poured through openings as at 50 and 5!, or pref- 50 erably the cavities may be filled with solder pellets and then heated to molten condition as by the use of external heating means such as above described in connection with Fig. 6. In either case parts which are intended to adhere and'treated with flux in a manner similar to that above described. As the solder is allowed to solidify, additional solder in solid or molten condition may be introduced through'the openings 50 and 5| to compensate for the contraction of the cooling metal and so that the cavities upon completion will be filled. In Fig. 5 the lefthand end of the joint is shown prior to the introduction of the solder and the r righthand end of the figure provides a cross sectional view of the seal after completion. In case the barriers as at 46, 41 are made of lead or other metal to which solder will adhere, the resulting seal at the end of the joint will in efiect take the form of an integral mass, including the end of the sleeve, the barriers and the cable sheath. If desired, he outer portions of the outer barriers may be rounded as at 52 and after the barriers are in place, the ends of the sleeve washer-like members leave the outer ends so that the same may ing means constructions may be beaten in to a correspondingly rounded degree as indicated at 53.

Another form of barrier means which may be used according to the invention is illustrated in Figs. 7 and 8. The joint here shown may be generally similar to that of Fig. 5, except that each barrier may comprise a pair of metallic as at 5% and 55, with internal and external. gaskets as at 55 and 5t clamped therebetween, each pair of barriers being secured together as by a plurality of threaded rods as at 58. The manner of using this construction will be apparent from the above descriptions. It will be understood that the'greater part of the solder of the embodiments of Figs. 5 to 8 inclusive if desired, may also be introduced in the form of precast solder walls similar to the precast solder members in Fig. 1. In fact, if desired, a precast solder member with the bar- '7 may be introduced as an assemled unit. If desired, with the arrangement of Fig. '1 the innermost gaskets 51 with the metallic clamping members therefor loosely engaging same, may be first introduced together with the rods 58 before the outermost gaskets and clamping members are applied to the rods. This will of the rods free for access be turned tocause the inner metallic washers to tightly clamp the inner' gaskets, thus expanding the gaskets into firm sealing relationship with the sleeve as shown. The inner nuts on the rods 58 may be soldered, welded or otherwise affixed to. the inner clamping members so that the nuts will not turn during this operation. After the inner gaskets are thus clamped in place, the outermost gaskets 51 and the clamptherefor may be readily applied and then clamped in position by the outer nuts on the rods 58. The members 55 and rods'58 are preferably made or plated with a suitable metal to which the solder will firmly adhere in sealing relationship to form in effect an integrally sealed end piece for the joint.

While the invention has been described in detail with respect to particular preferred examples,

it will be understood by those skilled in the art after understanding the invention that various changes and modifications may be made without departing from the spirit and scope of the invention, and it is intended therefore in the appended claims to cover all such changes and modifications. v

Certain features of the completed joint con- .struction are disclosed and claimed in applicants copending application Ser. No. 379,017, filed Feb ruary 15, 1941. Certain alternative methods and with which features of this invention may be'used are disclosed and claimed in applicants copending application Ser. No. 304,567, filed concurrently herewith.

What is claimed as new and desired .to be secured by Letters Patent is:

l. The method of sealing a cable having a metallic sheath, with respect to a metallic sleev surrounding same, which comprises introducing a pre-cast wall of solder into the spac between the sheath and the interior surface 0 the sleeve and also barriers at each side of sai wall to confine the solder when melted, and the temporarily applying heat internally of said wal from a source therein, to cause the solder to mel and adhere and become sealed in respect to sai surface and the sheath.

2. The method of sealing a cable having metallic sheath, with respect to a metallic sleev surrounding same, which comprises applying a pre-cast mass of solder around the sheath and extending to the sleeve at the location of the desired seal, then temporarily applying heat internally of said mass from a source therein, to cause the solder to melt and adhere and become sealed in respect to the sheath and sleeve.

3. The method of sealing and supporting a plurality of electric cables having lead sheaths, in respect to a lead sleeve into the end of which the cables extend in spaced relationship to each other and to the sleeve, which comprises introducing solder in its solid state at the location of the desired seal within the sleeve and also applying barriers at each side 'of said location to confine the solder when melted, providing apertures through said barriers to permit the cables to pass therethrough and whereby the cables are retained.

by the barriers in substantially fixed positions in respect to each other and the sleeve during the sealing operation, and then temporarily applying suficient heat to the solder to melt the same into sealing relationship with the sheaths and sleeve.

4. The method of sealing an electric cable having a lead sheath, in respect to a lead sleeve of substantially uniform cross section and into the end of which the cable extends in substantially spaced relation to the interior walls of the sleeve, which comprises p-re-casting a disc-like member of-solder which is apertured for passage of the cable therethrough, and the peripheral edges of which are adapted to substantially contact with the interior walls of the sleeve, apply= ing an apertured barrier member onto the cable and within the sleeve adjacent the desired location of the seal to prevent molten solder from flowing from said location further into the sleeve, placing said member of solder on the cable adja cent said barrier and temporarily applying sufi cient heat to said member sealing relationship with the sleeve and cable sheath.

5. The method of sealing a cable having metallic sheath, in respect to a metallic sleeve into the end of which the cable extends, which comprises pre-casting a disc-like member of solder which is apertured for passage of the cable therethrough, and the peripheral edges of which are adapted to substantially contact with the sleeve, providing cavities in said member for re= ceiving heating elements, then placing said mem= ber on the cable at the location or" the desired seal adjacent an end of the sleeve, and applmng heat in said cavities to melt the solder into seal-= ing relationship with the sleeve and cable sheath.

6. Means for sealing a cable joint construction comprising a pre-cast disc-like mass of solder, one or more apertures being formed therethreugh for passage of the cable or cables, and one er more cartridge-like members cast th rein for receiving heating means. i

Whalers-s. CONSTAmlE a,

to melt the solder into a 

